OK, I bought this bike a few months ago and have just started playing with it a little. The first thing I wanted to fix was the mirror mount on the fairing, the PO had dropped it in the trailer he stored it in and broke it.
I first cleaned out all the loose pieces, then marked where I could drill mounting holes.

Attachments

next came a paper pattern

the rough shape in stainless, yea it's rough

rough fitting the part

starting to look like something with pockets welded in

aluminum nut plates for the back side

fits tight

ready for the mirror, with stock nut plate also installed, came out very ridged. moral of this story.....don't break your mirror mount, it's a pain in the.......neck, yea neck will work

Thank you WingAdmin, yes if it falls on that side again it's going to take the whole side off the fairing. My friend was working on his bike the same time (you see his triumph tank I just finished painting in the background), and said " why didn't you make one for the other side at the same time? I told him to shut up and I would never need it because I'm not ever going to break it.

this repair worked good for the load that it will have to take, but I am wondering if any one has found a good way to repair ABS for regular bodywork. I have a small crack in a side bag and a corner to repair on a lid. I could replace them but if I can repair them...even better.
I have heard of melting pieces of ABS in ABS glue and making a paste. I know 3M makes a sytem and there is Plasti-fix, but I have never used them.
So....if anyone has used anything that works and holds up well, I would love to hear about it.
Thank you.

ABS plastic cement will not just "glue" the crack, but will melt the ABS plastic a tad bit becoming one piece again. Make sure it is ABS only! ABS plastic pipe shavings/pellets and MEK mixed in a Mason jar is virtually the same thing. I hope this helps you.
Alanc1100

86pearlblue, first, thank you.
What I did to make the pockets was first mark on my plate where the mount bolts hit.
I pre fit the plate by first marking on the fairing where I could drill holes, I tranferred those positions to my plate, that is the lines you see in the first couple pictures.
I drilled the holes in the plate first, then held it in place and drilled the fairing.
I then put two screws through, one at top one at bottom, no nuts needed this is just rough fitting.
I took the mount off the mirror and held it in place, I drew a circle around each mirror mount with a felt pen.
One I drilled out, the other I drilled around to make a "U" (see picture).
I then bent the "U" back until the mount boss fit pretty close.
The mirror mount boss now fit into the bent back "U" and the other mount boss protruded through the other hole. Now, holding the chrome trim for the windshield in place I measured from the plate to the tab (see pic of rough fit) to get my set back dimension, I measured at the top of the hole and the bottom, .220 out at top and .350 in at bottom in my case (you can see in picture how the pocket sticks out at top and sticks in at bottom).
I made a plate to fit the hole tacked it adjusted it to get my dimensions.
I then just cut strips about the width of the set back, bent them in "U" shapes, tigged them in place and ground off the excess.
Once I had the pockets formed I put it back on the bike, held the mirror mount in place and marked the holes for the mounting bosses.
I'm sorry if it sounds confusing, I wish I took a few pics of the fab stages.

deanbw wrote:this repair worked good for the load that it will have to take, but I am wondering if any one has found a good way to repair ABS for regular bodywork. I have a small crack in a side bag and a corner to repair on a lid. I could replace them but if I can repair them...even better.
I have heard of melting pieces of ABS in ABS glue and making a paste. I know 3M makes a sytem and there is Plasti-fix, but I have never used them.
So....if anyone has used anything that works and holds up well, I would love to hear about it.
Thank you.

When I have cracks to repair, my universal fix is either just ABS glue, or if it's a larger crack (or is structural), use ABS glue to bond (sister) another piece of ABS to the back of it. A lot of the time it fixes the cracks so well that you can no longer see where the crack was in the painted side.

Make sure however it is ABS glue, not PVC - the important element is MEK (methyl ethyl ketone) - that's the stuff that chemically "melts" the ABS. If you're in a fix, you can buy MEK at a hardware store, but it's a lot harder to work with than ABS glue.

Incidentally, if your ABS glue starts getting old and thick, adding some MEK to it makes it like new!

deanbw wrote:this repair worked good for the load that it will have to take, but I am wondering if any one has found a good way to repair ABS for regular bodywork. I have a small crack in a side bag and a corner to repair on a lid. I could replace them but if I can repair them...even better.
I have heard of melting pieces of ABS in ABS glue and making a paste. I know 3M makes a sytem and there is Plasti-fix, but I have never used them.
So....if anyone has used anything that works and holds up well, I would love to hear about it.
Thank you.

Hi there I did fix the luggage top box was cracked in two three pieces and covered by some kind of tape where I was not in able to see it during the time of purchase covered by the mate.First of all I did use very thin 20mm flat stain less still plate to put together the broken part and attached it by rebate.Any way I did research a lot to save money & I was not in able to find ABS cement but instead I got plumbers glue called PVC cement and it works great very happy I will edit and upload a photo so that some can see it what I come up with.
God bless!

Alemayehu wrote:Hi there I did fix the luggage top box was cracked in two three pieces and covered by some kind of tape where I was not in able to see it during the time of purchase covered by the mate.First of all I did use very thin 20mm flat stain less still plate to put together the broken part and attached it by rebate.Any way I did research a lot to save money & I was not in able to find ABS cement but instead I got plumbers glue called PVC cement and it works great very happy I will edit and upload a photo so that some can see it what I come up with.
God bless!

I hear ya!!!, when I took mine apart and found it broke, I thought, no way I'm buying a fairing just for that.....There has to be a way.
Take your time to fit it to the contour of the fairing and once on you will forget it was even fixed. Oh, and the indents just have to be close, depth is more important than angle. Best of luck.